Footwear with binding to couple outsole and upper

ABSTRACT

A footwear article comprises an outsole oriented to define a bottom of a footwear article and configured for ground contact, the outsole comprising natural rubber, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion, the sidewall terminating at an upper peripheral edge of the outsole, and wherein a thickness of the outsole measured through the upper peripheral edge is about 1.0 mm, a binding disposed over opposing sides of the upper peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam, an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam; and a midsole disposed adjacent the bottom portion of the outsole and at least partially surrounded by the upper portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Nonprovisional of U.S. Provisional Application Ser. No. 63/227,701, filed Jul. 30, 2021, which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to the field of footwear, and more particularly to articles and methods of making the same.

BACKGROUND

Conventional articles of athletic footwear generally include at least two components, namely, an upper and a sole structure. The upper is often secured to the sole structure and forms a void on the interior of the footwear for securely and comfortably receiving a foot.

The upper and sole structure of most conventional articles of footwear are permanently secured together through adhesive bonding or stitching, for example.

In contrast with the conventional article of footwear that includes a permanently secured upper and sole structure, footwear configurations embodying an upper and detachable sole structure have been proposed. As an example, U.S. Pat. No. 6,023,857 to Vizy et al. discloses footwear with a permanently attached upper and outsole that includes a separate midsole and heel counter structure, which is removable from the upper. As another example, U.S. Pat. No. 5,083,385 to Halford and U.S. Pat. No. 4,974,344 to Ching both disclose an outsole structure that is detachable from the remainder of the footwear. As a further example, U.S. Pat. Nos. 6,023,859 and 5,799,417 to Burke et al. disclose an article of footwear with removable and exchangeable inserts that are positioned between the upper and a lower portion of the sole structure. The inserts protrude through the lower portion of the sole structure to provide a ground-contacting surface.

Recreational and athletic footwear usually features a sophisticated combination of elements that provide optimal balance, comfort, stability, durability and traction for a wearer. Generally, a wearer may expect footwear to have a certain resilience and may expect to use certain types of footwear on varying surfaces or ground conditions. For these purposes, traction and durability are important aspects of footwear and can depend directly on the composition of the outsole of an article of footwear. There remains a need in the art for an outsole composition that provides optimal traction and durability while maintaining other desirable aspects of footwear such as comfort, stability, and balance, as well as aesthetic preferences.

Improvements over the prior art are needed.

SUMMARY

A footwear article comprises an outsole oriented to define a bottom of a footwear article and configured for ground contact, the outsole comprising natural rubber, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion, the sidewall terminating at an upper peripheral edge of the outsole, and wherein a thickness of the outsole measured through the upper peripheral edge is about 1.0 mm; a binding disposed over opposing sides of the upper peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam; and a midsole disposed adjacent the bottom portion of the outsole and at least partially surrounded by the upper portion.

A footwear article may comprise an outsole oriented to define a bottom of a footwear article and configured for ground contact; a binding disposed over opposing sides of a peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; and an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam.

A method of making a footwear article may comprise forming an outsole to define a bottom of a footwear article and configured for ground contact, disposing a binding over opposing sides of a peripheral edge of the outsole, and coupling an upper portion to the binding and the outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings show generally, by way of example, but not by way of limitation, various examples discussed in the present disclosure. In the drawings:

FIG. 1 is an exploded perspective view of a footwear article in accordance with the present disclosure.

FIG. 2 illustrates a partial exploded view of the footwear article of FIG. 1 showing a binding partially secured to an outsole in accordance with the present disclosure.

FIG. 3 illustrates the footwear article of FIG. 1 showing an upper secured to an outsole via a binding secured to the outsole in accordance with the present disclosure.

FIG. 4 illustrates a perspective view of the assembled footwear article of FIG. 1 .

DETAILED DESCRIPTION

The present disclosure relates to footwear articles comprising an outsole oriented to define a bottom of a footwear article and configured for ground contact. As an example, the outsole may comprise or be formed from a natural rubber. The outsole may have a cupsole shape including a bottom portion and a sidewall extending upwardly from the bottom portion. An upper portion may be coupled to the sidewall of the outsole. However, where the outsole is formed from natural rubber, the coupling of the upper portion directly to the outsole sidewall may not be suitable. For example, the tear strength of a thin portion of the sidewall of the outsole may allow the upper portion to pull away from the outsole. As such, a binding may be used. As an example, a binding may be disposed over opposing sides of a peripheral edge of the outsole. Then, the upper portion may be coupled (e.g., stitched) to the binding and the outsole, wherein the binding provides additional strength and resistance to tearing.

As an illustrative example, the binding may provide the structure that allows the stitching to keep the upper portion firmly attached to the outsole without ripping through the thin rubber lip along the top (peripheral edge) of the outsole.

As a further example, components of the footwear article may comprise laces, an upper portion, an insole, a midsole and an outsole. The upper portion may be oriented at the top of the assembled footwear and the outsole may be oriented at the bottom of the assembled footwear, and may be configured for ground contact. The insole may be located in-between the upper portion and the outsole and the midsole may be located in-between the insole and the outsole. The footwear may be assembled with additional components or without all of the listed components present. The components of the footwear may be made from the same material or from different materials. The components of the footwear may be made from the same recyclable material or from different recyclable materials. The components of the footwear may be coupled to one another with thread using stitching or other sewing methods that may easily be disassembled. As such, the components of the footwear article may be disassembled for reuse or recycling.

FIGS. 1-4 illustrate an example footwear article 100. As shown, the footwear article 100 may comprise an outsole 102, an upper portion 104, a binding 106, and/or a midsole 108. Other components may be included.

The outsole 102 may be oriented to define a bottom of the footwear article 100 and may be configured for ground contact. The outsole 102 may comprise natural rubber. The outsole 102 may comprise a cupsole shape having a bottom portion 112 and a sidewall 114 extending from a periphery of the bottom portion 112. The sidewall 114 may terminate at a peripheral edge 110 (e.g., upper peripheral edge relative to the bottom portion 112) of the outsole 102. The sidewall 114 may have variable thickness. The sidewall 114 may comprise a lip 116. The sidewall 114 of the outsole 102 may have variable thickness with the thinnest portion measured through the peripheral edge 110. The thickness of the outsole 102 measured through the peripheral edge 110 may be about 1.0 mm.

The binding 106 may comprise a textile or may be derived from a textile. The textile may have a thickness from 0.3 mm-1.0 mm. Other textiles and thickens may be used. Other materials may be used. The binding 106 may be disposed over opposing sides of the peripheral edge 110 of the outsole. As an example, the binding 106 may be folded over the peripheral edge 110 of the outsole 102. The binding 106 may be coupled to the side wall 114 to cover the peripheral edge 110 of the outsole 102. As an example, the binding 106 may be stitched to the outsole 102 (e.g., at the sidewall 114) along a first stitch seam 118.

The upper portion 104 may comprise one or more of cotton, hemp, or nylon, or a combination thereof. Other materials may be used. The upper portion 104 may be coupled (e.g., stitched) to the binding 106. The upper portion 104 may be coupled (e.g., stitched) to the binding 106 and the outsole 102. The upper portion 104 may be coupled (e.g., stitched) to the binding 106 along a second stitch seam 120. The second stitch seam 120 may be adjacent the first stitch seam 118. As an example, the second stitch seam 120 may be disposed above the first stitch seam 118 relative to the bottom portion 112 of the outsole 102.

The midsole 108 may be disposed adjacent the bottom portion 112 of the outsole 102 and may be at least partially surrounded by the upper portion 104. The midsole 108 may be bio-based. The midsole 108 may comprise a bio-based foam. The midsole 108 may comprise a bio-based foam derived from vegetable oil.

The present disclosure relates to methods of making a footwear article. An example method may comprise forming an outsole to define a bottom of a footwear article and configured for ground contact. The outsole may be formed from natural rubber or a natural rubber compound. A binding may be disposed over opposing sides of a peripheral edge of the outsole, such as over the top peripheral edge, for example. As such, an upper portion may be coupled to the binding or to the binding and the outsole.

The present disclosure comprises at least the following aspects:

Aspect 1: 1. A footwear article comprising: an outsole oriented to define a bottom of a footwear article and configured for ground contact, the outsole comprising natural rubber, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion, the sidewall terminating at an upper peripheral edge of the outsole, and wherein a thickness of the outsole measured through the upper peripheral edge is about 1.0 mm; a binding disposed over opposing sides of the upper peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam; and a midsole disposed adjacent the bottom portion of the outsole and at least partially surrounded by the upper portion.

Aspect 2. The footwear article of aspect 1, wherein the binding is formed from a textile.

Aspect 3. The footwear article of any one of aspects 1-2, wherein the binding is folded over the upper peripheral edge of the outsole and coupled to cover the upper peripheral edge of the outsole.

Aspect 4. The footwear article of any one of aspects 1-3, wherein the upper portion comprises one or more of cotton, hemp, or nylon, or a combination thereof.

Aspect 5. The footwear article of any one of aspects 1-4, wherein the midsole is bio-based.

Aspect 6. The footwear article of any one of aspects 1-4, wherein the midsole comprises a bio-based foam.

Aspect 7. The footwear article of any one of aspects 1-4, wherein the midsole comprises a bio-based foam derived from vegetable oil.

Aspect 8. The footwear article of any one of aspects 1-7, wherein the second seam is disposed above the first seam relative to the bottom portion of the outsole.

Aspect 9. The footwear article of any one of aspects 1-8, wherein the sidewall of the outsole has variable thickness, with the thinnest portion measured through the upper peripheral edge.

Aspect 10. The footwear article of any one of aspects 1-9, wherein the sidewall of the outsole comprises a lip defined along the upper peripheral edge.

Aspect 11. A method of making the footwear article of any one of aspects 1-10.

Aspect 12. A footwear article comprising: an outsole oriented to define a bottom of a footwear article and configured for ground contact; a binding disposed over opposing sides of a peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; and an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam.

Aspect 13. The footwear article of aspect 12, wherein the outsole comprises natural rubber.

Aspect 14. The footwear article of any one aspects 12-13, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion.

Aspect 15. The footwear article of aspect 14, wherein the sidewall terminates at the peripheral edge of the outsole.

Aspect 16. The footwear article of aspect 15, wherein a thickness of the outsole measured through the peripheral edge is about 1.0 mm.

Aspect 17. The footwear article of any one aspects 12-16, wherein the binding is formed from a textile.

Aspect 18. The footwear article of any one aspects 12-17, wherein the binding is folded over the peripheral edge of the outsole and coupled to cover the peripheral edge of the outsole.

Aspect 19. The footwear article of any one aspects 12-18, wherein the upper portion comprises one or more of cotton, hemp, or nylon, or a combination thereof.

Aspect 20. The footwear article of any one aspects 12-19, further comprising a midsole disposed adjacent the outsole and at least partially surrounded by the upper portion.

Aspect 21. The footwear article of aspect 20, wherein the midsole comprises a bio-based foam.

Aspect 22. The footwear article of aspect 20, wherein the midsole comprises a bio-based foam derived from vegetable oil.

Aspect 23. The footwear article of any one aspects 12-22, wherein the second seam is disposed above the first seam relative to a bottom portion of the outsole.

Aspect 24. The footwear article of any one aspects 12-23, wherein the outsole has variable thickness with the thinnest portion measured through the peripheral edge.

Aspect 25. The footwear article of any one aspects 12-24, wherein the outsole comprises a lip defined along the peripheral edge.

Aspect 26. A method of making the footwear article of any one of aspects 12-25.

Aspect 27. A method of making a footwear article, the method comprising: forming an outsole to define a bottom of a footwear article and configured for ground contact; disposing a binding over opposing sides of a peripheral edge of the outsole; and coupling an upper portion to the binding and the outsole.

Aspect 28. The method of aspect 27, wherein the binding is stitched to the outsole along a first stitch seam.

Aspect 29. The method of any one of aspects 27-28, wherein the upper portion is stitched to the binding and the outsole along a second stitch seam.

Aspect 30. The method of any one of aspects 27-29, wherein the outsole comprises natural rubber.

Aspect 31. The method of any one of aspects 27-30, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion.

Aspect 32. The method of aspect 31, wherein the sidewall terminates at the peripheral edge of the outsole.

Aspect 33. The method of aspect 32, wherein a thickness of the outsole measured through the peripheral edge is about 1.0 mm.

Aspect 34. The method of any one of aspects 27-33, wherein the binding is formed from a textile.

Aspect 35. The method of any one of aspects 27-34, wherein disposing the binding comprises folding the binding over the peripheral edge of the outsole and coupling the binding to the outsole to cover the peripheral edge of the outsole.

Aspect 36. The footwear article of any one of aspects 27-35, wherein the upper portion comprises one or more of cotton, hemp, or nylon, or a combination thereof.

Aspect 37. The footwear article of any one of aspects 27-36, wherein the midsole is bio-based.

Aspect 38. The method of any one of aspects 27-36, wherein the midsole comprises a bio-based foam.

Aspect 39. The method of any one of aspects 27-36, wherein the midsole comprises a bio-based foam derived from vegetable oil.

Aspect 40. The method of any one of aspects 27-39, wherein the sidewall of the outsole has variable thickness with the thinnest portion measured through the peripheral edge.

Aspect 41. The method of any one of aspects 27-40, wherein the sidewall of the outsole comprises a lip defined along the peripheral edge.

Although shown and described in what is believed to be the most practical and preferred embodiments, it is apparent that departures from specific designs and methods described and shown will suggest themselves to those skilled in the art and may be used without departing from the spirit and scope of the invention. The present invention is not restricted to the particular constructions described and illustrated but should be constructed to cohere with all modifications that may fall within the scope of the appended claims. 

What is claimed is:
 1. A footwear article comprising: an outsole oriented to define a bottom of a footwear article and configured for ground contact, the outsole comprising natural rubber, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion, the sidewall terminating at an upper peripheral edge of the outsole, and wherein a thickness of the outsole measured through the upper peripheral edge is about 1.0 mm; a binding disposed over opposing sides of the upper peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam; and a midsole disposed adjacent the bottom portion of the outsole and at least partially surrounded by the upper portion.
 2. The footwear article of claim 1, wherein the binding is formed from a textile.
 3. The footwear article of claim 1, wherein the upper portion comprises one or more of cotton, hemp, or nylon, or a combination thereof.
 4. The footwear article of claim 1, wherein the midsole comprises a bio-based foam.
 5. The footwear article of claim 1, wherein the second seam is disposed above the first seam relative to the bottom portion of the outsole.
 6. The footwear article of claim 1, wherein the sidewall of the outsole has variable thickness, with the thinnest portion measured through the upper peripheral edge.
 7. The footwear article of claim 1, wherein the sidewall of the outsole comprises a lip defined along the upper peripheral edge.
 8. A footwear article comprising: an outsole oriented to define a bottom of a footwear article and configured for ground contact; a textile binding disposed over opposing sides of a peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam and folded over the peripheral edge of the outsole and coupled to cover the peripheral edge of the outsole; and an upper portion stitched to the binding and the outsole along a second stitch seam adjacent the first stitch seam.
 9. The footwear article of claim 8, wherein the outsole comprises natural rubber.
 10. The footwear article of claim 8, wherein the outsole comprises a cupsole shape having a bottom portion and a sidewall extending from a periphery of the bottom portion.
 11. The footwear article of claim 8, wherein the sidewall terminates at the peripheral edge of the outsole.
 12. The footwear article of claim 8, wherein a thickness of the outsole measured through the peripheral edge is about 1.0 mm.
 13. The footwear article of claim 8, wherein the upper portion comprises one or more of cotton, hemp, or nylon, or a combination thereof.
 14. The footwear article of claim 8, further comprising a midsole disposed adjacent the outsole and at least partially surrounded by the upper portion.
 15. The footwear article of claim 8, wherein the midsole comprises a bio-based foam.
 16. The footwear article of claim 9, wherein the second seam is disposed above the first seam relative to a bottom portion of the outsole.
 17. The footwear article of claim 8, wherein the outsole has variable thickness with the thinnest portion measured through the peripheral edge.
 18. The footwear article of claim 8, wherein the outsole comprises a lip defined along the peripheral edge.
 19. A method of making a footwear article, the method comprising: forming an outsole to define a bottom of a footwear article and configured for ground contact; disposing a binding over opposing sides of a peripheral edge of the outsole, wherein the binding is stitched to the outsole along a first stitch seam; and coupling an upper portion to the binding and the outsole.
 20. The method of claim 19, wherein the upper portion is stitched to the binding and the outsole along a second stitch seam. 